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Introduction to Mechanical Engineering Design

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6 views

Introduction to Mechanical Engineering Design

Uploaded by

teektak1
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Introduction to Mechanical

Engineering Design
Ashraf Fahmy
Presentation Contents:
• Main Topic
• Lecture Aim
• Motivation of the Topic
• Pedagogical Approach
• What is Design
• Mechanical Engineering Design
• Electric Vehicle Design Example
• Full Product Design Optimization
• EV Powertrain Design Optimisation
• Computational Model Development
• Optimisation Problem Formulation
Main Topic:
• The main topic for this lecture is to provide
introduction to the mechanical design process, that
requires many engineering skills.
• Device or equipment sub-system relationships need to
be divided into a series of simple design tasks.
• Design is an innovative and highly iterative process with
many interactive phases.
• The complexity of the process requires a sequence in
which ideas are introduced, iterated, developed, and
optimized.
Lecture Aim:
• The aim of the lecture is to provide an introduction on the
mechanical design process.
• The roles of codes, standards, tolerances, reliability, current
economics, safety, and product liability.
• The survival of a mechanical device that is related to
stresses and material strength.
• Design factor and safety factor for addressing uncertainty in
mechanical design using deterministic (absolute) or
statistical methods.
• Demonstrate an example of EV design process.
Motivation of the Topic:
• The motivation of this topic in Mechanical Engineering design
is related to:
Mechanical Engineering is very important for manufacturing
processes, people and goods land, sea, sub-sea, and air
transportation, agriculture equipment manufacturing, domestic
services, mobility assistance, and many every day use
equipment from home appliances to moving stairs, elevators,
and commercial assistive food and beverage equipment.
Global competition forces Mechanical Design to be innovative,
reliable, and in continuous development.
Pedagogical Approach:
• The pedagogical approach we are going to implement within the module
delivery is as follow:
• We will depend on the theory of liberal education to develop your
potential in mechanical design engineering as well as vocational education
to allow you to impart and acquire specific design and innovation skills.
• The course tutor will act as knowledge facilitator while the student well act
as the knowledge seeker.
• Fundamental knowledge and skills will be deployed to you through
lectures, tutorial videos, and design assignments.
• Student pre-preparation for the next lecture topic contents will be also
used for personal knowledge seeking before conducting actual lecture
presentation.
Pedagogical Approach:
• The pedagogical approach we are going to implement within the
module assessment is as follow:
• The pre-preparation will be self-assessed by the student after the
lecture and by the tutor based on pre-defined assessment criteria.
• Assessment will be done using on lecture quizzes, individual and
group design exercises with student-to-student random evaluation of
the design based on a pre-defined assessment criteria with final
assessment from the course tutor.
• Real world design challenging tasks will be distributed to individual
students to plan a complete, detailed, and optimization process.
What is Design:
• To design is to formulate a plan to provide or satisfy a
specified need or to solve a specific problem.
• Creating a product of physical reality, means that it must be
functional, safe, reliable, competitive, usable,
manufacturable, and marketable.
• Design is also a decision-making process, where decisions
sometimes have to be made with too little information.
• Decisions are sometimes made tentatively, with the reserve
to be adjusted as more information becomes available.
Mechanical Engineering Design:
• Mechanical design is to produce and process mechanical energy
associated with automation techniques.
• Design bases are related to mechanics of solids, fluids,
manufacturing processes, electrical, sensors, and information
technology.
• A simple bearing design involves fluid flow, heat transfer, friction,
energy transport, material selection, thermomechanical
treatments, and so on.
• The string that precede the word design is merely “Product
description”.
Electric Vehicle Design Example:
• Design of Body Shape, weight, material selection, safety,
functionality, comfort, permissible load, required speed,
operating range…..etc.
• Separate design of components such as Motors, Battery,
Converter, Regenerative Breaking, Control and monitoring
system, ….etc.
• Overall system performance evaluation, reconsideration of
elements, and overall performance and cost optimization.
Electric Vehicle Design Example:
Full Product Design Optimization:
Reduce the costs associated
with powertrain design,
manufacturing, and assembly of
EV.
The complexity of this problem
with its associated numerous
optimisation variables requires
simplification of
vehicle/powertrain models.
EV Powertrain Design Optimisation:

Constraints Target
Computational Model Development:

𝑿𝑿 = [𝑥𝑥1, 𝑥𝑥2, 𝑥𝑥3, … 𝑥𝑥𝑚𝑚 ]


Optimisation Problem Formulation:

• The EV drivetrain design optimisation may be formulated as:


fj : linear in x or not?

𝑚𝑚𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖𝑖 𝑓𝑓(𝑥𝑥)
6 What actions could be
𝑥𝑥𝑖𝑖 𝑓𝑓 𝑥𝑥 = � 𝑓𝑓𝑗𝑗 (𝑥𝑥) taken on (𝑥𝑥𝑖𝑖 ) to
𝑗𝑗=1 f1: Battery cost minimise the EV cost?
𝑙𝑙𝑏𝑏 ≤ 𝑥𝑥𝑖𝑖 ≤ 𝑢𝑢𝑢𝑢 𝑖𝑖 = 1, 23 f2: Gearbox cost Eg: 𝑥𝑥𝑖𝑖 = 𝑥𝑥𝑖𝑖 + 𝜖𝜖𝑖𝑖
𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 𝑡𝑡𝑡𝑡
? ? ≤ 𝑥𝑥𝑖𝑖 ≤? ? 𝑖𝑖 = 24, … , 𝑵𝑵? f3: Motor Baseline cost
f4: Magnet cost
f5: Inverter Baseline cost
f6: Control cost
Any Questions?

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